design and manufacture of vetrical- axis … axis wind turbines are further subdivided into two...

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 6, November–December 2016, pp.86–95, Article ID: IJMET_07_06_009

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ISSN Print: 0976-6340 and ISSN Online: 0976-6359

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DESIGN AND MANUFACTURE OF VETRICAL- AXIS

WIND TURBINE BASED ON MAGNETIC LEVITATION

Rajasri Alloli

M. Tech Student, Department of Mechanical Engineering,

Anurag Group of Institutions, Ghatkesar, Telangana, India

Pratibha Dharmavarapu

Assistant Professor, Department of Mechanical Engineering,


Chunchu Sravanthi

Assistant Professor, Department of Mechanical Engineering,


ABSTRACT

The goal of this project is to build the vertical axis wind turbine to generate electricity by using

wind energy. This type of vertical axis wind turbine will generate electricity without using

generator or alternator, But by the application of magnetic levitation concept.

This wind turbine is designed to sustain all the forces by wind and to keep the wings of the

turbine rotating even though there is low wind force. This type of vertical axis wind turbines has

three wings which are attached to the rotating shaft. The wings are designed that they accept the

wind which comes from any directions. This project contains design and prototype of vertical axis

wind turbine.

Key words: Vertical axis wind turbine, Wind energy, Magneti levitation and Alternator.

Cite this Article: Rajasri Alloli, Pratibha Dharmavarapu and Chunchu Sravanthi, Design and

Manufacture of Vetrical- Axis Wind Turbine Based on Magnetic Levitation. International Journal

of Mechanical Engineering and Technology, 7(6), 2016, pp. 86–95.

http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=6

1. INTRODUCTION

Renewable energy is generally electricity supplied from sources, such as wind power, solar power,

geothermal energy, hydropower and various forms of biomass. These sources have been coined renewable

due to their continuous replenishment and availability for use over and over again. The popularity of

renewable energy has experienced a significant upsurge in recent times due to the exhaustion of

conventional power generation methods and increasing realization of its adverse effects on the

environment. A wind turbine basically draws the kinetic energy from the wind and converts this power to

electrical energy by means of a generator.

Design and Manufacture of Vetrical- Axis Wind Turbine Based on Magnetic Levitation


This project focuses on the utilization of wind energy as a renewable source. In the United States alone,

wind capacity has grown about 45% to 16.7GW and it continues to grow with the facilitation of new wind

projects. The aim of this major qualifying project is to design and implement a magnetically levitated

vertical axis wind turbine system that has the ability to operate in both high and low wind speed

conditions. Our choice for this model is to showcase its efficiency in varying wind conditions as compared

to the traditional horizontal axis wind turbine and contribute to its steady growing popularity for the

purpose of mass utilization in the near future as a reliable source of power generation.

2. TYPES OF WIND TURBINES

Many types of turbines exist today and their designs are usually inclined towards one of the two categories:

horizontal-axis wind turbines (HAWTs) and vertical-axis wind turbines (VAWTs). As the name pertains,

each turbine is distinguished by the orientation of their rotor shafts. The former is the more conventional

and common type everyone has come to know, while the latter due to its seldom usage and exploitation, is

quiet unpopular.

2.1. HAWT

The HAWTs usually consist of two or three propeller-like blades attached to a horizontal and mounted on

bearings the top of a support tower as seen When the wind blows, the blades of the turbine are set in

motion which drives a generator that produces AC electricity. For optimal efficiency, these horizontal

turbines are usually made to point into the wind with the aid of a sensor and a servo motor or a wind vane

for smaller wind turbine applications.

2.2. VAWT

Vertical axis wind turbines are further subdivided into two major types namely the Darrieus model and the

Savonius model. With the vertical axis wind turbines, the concept behind their operation is similar to that

of the horizontal designs. The major difference is the orientation of the rotors and generator which are all

vertically arranged and usually on a shaft for support and stability. This also results in a different response

of the turbine blades to the wind in relation to that of the horizontal configurations. Darrieus Model which

was named after designer and French aeronautical engineer, Georges Darrieus. This form of this design is

best described as an eggbeater with the blades, two or three of them bent into a c-shape on the shaft.

2.3. Magnetic Levitation

In selecting the vertical axis concept for the wind turbine that is implemented as the power generation

portion of this project, certain uniqueness corresponded to it that did not pertain to the other wind turbine

designs. The characteristic that set this wind generator apart from the others is that it is fully supported and

rotates about a vertical axis. This axis is vertically oriented through the center of the wind sails, which

allows for a different type of rotational support rather than the conventional ball bearing system found in

horizontal wind turbines.

3. PROJECT OBJECTIVE

The goal of this project is to build the vertical axis wind mill to generate electricity by using wind energy.

This type of vertical axis wind mill will generate electricity without using generator and alternator. By the

application of magnetic levitation electricity will be generated.

Magnetic levitation reduced wind mill weight acting by the gravitational force. This wind mill will be

designed to sustain all the forces by wind. The main advantage of this wind mill is cost is very low as

compared to other. This type of vertical axis wind mill has three vanes or blades, which are attached to the

shaft. The vanes or blades are will be designed like they should accept wind coming from all the directions.

Rajasri Alloli, Pratibha Dharmavarapu and Chunchu Sravanthi

http://www.iaeme.com/IJMET

4. DESIGN AND MANUFACTU

4.1. STATOR

Stator is a part which consists of enameled copper coils. Drawing with dimensions and 3D design of a

stator shown in below figures.

4.2. Manufacturing Process

Coil Design : The coils must be correctly designe

voltage, which will be the same as the battery bank voltage. Please see ‘WT_Model_Electrical_Design’ for

more details) and the correct current.

affect the thickness of the wire used.

Repeat to produce 12 coils, all as similar as possible.

One check to see if all the coils have the same number of turns is to weigh each coil in turn. Weight

differences greater than 5% suggest that the coils are not the same.


IJMET/index.asp 88

DESIGN AND MANUFACTURE OF COMPONENTS


Figure 1 Stator 3D pic

The coils must be correctly designed for the required output voltage (this is the system


more details) and the correct current. The voltage will affect the number of turns of wire, the

affect the thickness of the wire used.

Figure 2 Coil winding.

s, all as similar as possible.


than 5% suggest that the coils are not the same.


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d for the required output voltage (this is the system


The voltage will affect the number of turns of wire, the current will




Joining the coils: Once the coils are made they must be joined together ready for setting in resin. Firstly,

scratch off the enamel from the end 1cm of the two wires from each coil. The coils should then be laid out

as shown below, in a circle. It is best to use a large sheet of paper with the circle drawn on to ensure the

coils are kept at the correct distance. Ensure that all the coils are positioned the same way around, with the

inner wire and outer wire from each coil in the same position as others.

Cast the stator: Once the coils have been connected they must be cast in a resin mixture with some fibre-

glass to add strength. This will provide mechanical strength and waterproofing for the stator coils.

Figure 3 Mold

Procedure

The stator casting process is as follows. It is best to have a ‘dry run’ without any resin to ensure that

everything will go smoothly.

• Check the mould and ensure all the pieces (base, outer, centre, lid, nuts and bolts) are ok.

• Put a ring of silicon sealant around the base to seal the base to the outer section and the base to the

centre piece. Ensure these are in the correct position by using the bolts to line them up. The silicon

sealant will stop any of the resin from leaking out of the mould.

• Cover the area where the stator will be produced with scrap newspaper.

• The mould then requires waxing to ensure that the stator is released easily and will not stick to the

mould. ‘Wax’ is used for this purpose. This must be applied liberally with a soft cloth. Ensure all

surfaces that may be exposed to resin are covered. This must then be buff dried using a clean cloth or

electric buffer. Repeat this process at least five times so that a thick layer of wax is built up. The mould

can then be used.

• Next cut out two pieces of chopped strand fibre glass mat. These should be cut to the same size as the

stator, with a hole in the middle. Use the mould as a template to draw on the fibre-glass mat and then cut

slightly inside the line to ensure the mat fits comfortably into the mould.

4.3. Rotor Disks Design and Manufacturing

A rotor is rotating part of a mechanical device, for example in an electric motor, generator, alternator or

pump. It operates with a stationary element so called stator.

CREO 3D PIC: The tools we used to design this rotor disks in CREO 2.0 are PART MODELING and

ASSEMBLING.



Manufacturing Process: The material used for the manufacturing of ROTOR is mild steel, accor

the design dimensions the rotor has been produced with the laser cutting technology

Laser cutting Technology: Laser cutting

used for industrial manufacturing applications, but i

and hobbyists.

After the laser cutting process neodymium magnets are placed on the rotor disks with the h

Araldite hardener as shown in the below figures.


IJMET/index.asp 90

Figure 4 Rotor 3D model

The material used for the manufacturing of ROTOR is mild steel, accor

the design dimensions the rotor has been produced with the laser cutting technology

Laser cutting is a technology that uses a laser to cut materials, and is typically

used for industrial manufacturing applications, but is also starting to be used by schools, small businesses,

Figure 5 Laser cutting technology

After the laser cutting process neodymium magnets are placed on the rotor disks with the h

ite hardener as shown in the below figures.


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The material used for the manufacturing of ROTOR is mild steel, according to

the design dimensions the rotor has been produced with the laser cutting technology.

to cut materials, and is typically

s also starting to be used by schools, small businesses,

After the laser cutting process neodymium magnets are placed on the rotor disks with the help of



Figure 6 Rotor Assembly

4.4. Blades and Wings Design and Analysis

The blades are designed on the basis of Airfoils.

3D Figures: The below figures are of two different design blades use in this project.

Figure 7 3D figures of Blades

Manufacturing: The material used to manufacture the blades is mild steel. The blade cutting with given

dimensions is done by the laser cutting process.

Airfoils analysis: Structure Analysis

Parameters for structural analysis

Parameters Values Units

Force 3072.16 N

Velocity 6 m/s

Attack angle of Blade 31º

Surface area of the blade 715310 * 10-6

m2

Density of air 1.125 Kg/m2



Equivalent Stress:

Total deformation

5. ASSEMBLY OF VAWT

There are five subassemblies included in this VAWT assembly, they are

• Base assembly.

• Wing assembly.

• Magnet assembly.

• Rotor and Stator assembly.

• Support blade assembly.

5.1. Base Assembly

In the first step of this assembly the

welding. Next the base plate is welded on the top of base pole.

Ribs are welded to the foundation plate and base plate at right angle to the base pole with arc welding

to increase the strength of base assembly.

Bush and a shaft are assembled on the top of the base plate and welded together with arc assembled on

the top of the base plate and welded together with arc welding. Bush supports the shaft and holds it in its

position.


IJMET/index.asp 92

Equivalent Stress: Equivalent Strain

otal deformation Saftey Factor

There are five subassemblies included in this VAWT assembly, they are

Rotor and Stator assembly.

Support blade assembly.

In the first step of this assembly the base pole is mounted and welded on the foundation plate with the arc

welding. Next the base plate is welded on the top of base pole.


rength of base assembly.




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Equivalent Strain

Saftey Factor

base pole is mounted and welded on the foundation plate with the arc




Design and Manufacture of Vetrical


5.2. Wing Assembly

Two different types of blades of thickness 4mm are assembled to the vertical bars of 10mm thickness

which has slots, through press fit blades are fixed and are welded together with arc welding.

1mm thickness is bent in required shape and is welded to the bars with arc welding.

5.3. Magnet Assembly

12 Neodymium magnets are placed on one side of the rotor disk at regular angles with alternate poles

facing the rotor disk. Another 12 Neodymium magnets are placed on one side rotor which faces the rotor at

regular angels with alternate poles facing the rotor.

The north pole of the magnet on the first rotor has to face the south pole of the magnet on the rotor.

Design and Manufacture of Vetrical- Axis Wind Turbine Based on Magnetic Levita

IJMET/index.asp 93

Figure 8 Base assembly of VAWT


which has slots, through press fit blades are fixed and are welded together with arc welding.

kness is bent in required shape and is welded to the bars with arc welding.

Figure 9 VAWT Wing assembly


her 12 Neodymium magnets are placed on one side rotor which faces the rotor at

regular angels with alternate poles facing the rotor.


Axis Wind Turbine Based on Magnetic Levitation

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which has slots, through press fit blades are fixed and are welded together with arc welding. M.S sheet of

kness is bent in required shape and is welded to the bars with arc welding.


her 12 Neodymium magnets are placed on one side rotor which faces the rotor at




These magnets on the rotor disks are placed at regular angels with the help of thermocol sheet so that the

placement of the magnets doesn’t differ on both the rotor disks.

5.4. Rotor and Stator Assembly

Stator is place in between the two rotors as below shown in the figure. Rotor should be assembled in such a

way that rotor and stator should have some distance in between them. The North facing of magnet on

upper rotor disk has to face the south facing of magnet on the lower rotor disk.

Figure 10 Rotor and Stator assembly

5.6. Main Assembly

• Main assembly will be done in following steps.

• The rotor and stator assembly fixed to the base assembly with the help of bolts, nuts, spacers

and washers.

• Next all support blades are attached to the rotor assembly with the help of bolts and nuts.

• Wings are attached to the support blades.

Figure 11 VAWT Final Assembly



6. CONCLUSION

At the end of the project, the magnetically levitated vertical axis wind turbine was a success. The rotors

that were designed harnessed enough air to rotate at high wind speeds while keeping the centre of mass

closer to the base yielding stability. The wind turbine rotor levitated properly using permanent neodymium

magnets, which allowed for a smooth rotation with negligible friction producing the electro motive forces

which are cut by stator winding generating the electric energy.

REFERENCE

[1] Gasch R, Twele J. Wind power plants – fundamentals, design, construction and operation: Springer,

2012.

[2] Dinesh N Nagarkar and Dr. Z. J. Khan,”Wind Power Plant Using Magnetic Levitation Wind Turbine”,

International Journal of Engineering and Innovative Technology (IJEIT) Volume 3, Issue1, July 2013.

[3] Liu Shuqin”Magnetic Suspension and Self-pitch for Vertical-axis Wind Turbines”,

ISBN:http://www.intechopen.com/books/fundamentaland-advanced-topics-in-wind-

power/magneticsuspensionand-self-pitch-for-vertical-axis-windturbines.2011.

[4] Design and Fabrication of a Vertical Axis Wind Turbine, University of Notre Dame.

[5] Maglev wind turbine technologies, Inc. MWTT) & Off Grid Technologies, Inc. (OGT),” Vertical Axis

Wind Turbine 200 Mega Watt off Shore Wind Farm (VAWT of Shore JV)-City of Evanston, Illinois

Lake Michigan Project.

[6] Wind Turbine Stator Guide, sibat (sibol ng agham at technolohi ya) wellspring of Science and

Technology).

[7] AR.Saravanan, K.K.Padmanabhan, Design and Techno- Economic Evaluation of Small Wind Turbine

Usage in Indian Power Systems. International Journal of Mechanical Engineering and Technology

(IJMET), 3(1), 2012, pp. 127–141

[8] Piyush Gulve and Dr. S.B.Barve. Design and Construction of Vertical Axis Wind Turbine, International

Journal of Mechanical Engineering and Technology (IJMET), 5(10), 2014, pp. 148-155.

[9] Ramu S, Abhilash M, Ajay M, Aravind S and Hariprasad M , Low Expense Vertical Axis Wind Turbine

Using Permanent Magnets . International Journal of Mechanical Engineering and Technology (IJMET)

, 7(2), 2016, pp. 244 – 260 .

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